Decking System

ABSTRACT

A decking system comprises a plurality of deck planks interconnected such that at least 60% of a surface of the deck plank system comprises openings to allow pass through of at least one of an environmental condition, such as, air, sunlight, rain, etc. The deck plank openings result from a plurality of evenly spaced parallel rib elements that span across from one side of the deck plank to the other side, wherein the spacing between the rib elements provides the pass through openings, and the rib elements are fixed and supported in their orientation by a plurality of rib spacers and U-shaped support tabs between the rib elements. The openings adjacent a first and second length side, comprise a plurality of regularly spaced, recessed fastening supports within them. The deck planks also comprise a plurality of inter-locking tabs at an external perimeter to facilitate assembly of the deck plank system.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to a decking system, more specifically, the present disclosure is directed towards a decking system that conforms to specific federal guidelines currently unavailable in the market and prior art.

BACKGROUND OF THE DISCLOSURE

Decking systems are well known in the art and have been around for centuries. Typically, decking systems are used as outdoor flooring primarily for piers, docks, walkways, gangways, and the like. They are generally constructed from natural wood materials, cut to length, and assembled into the desired configuration. The downside of natural wood materials is that they have a limited life span due to extreme and cyclical outdoor environmental conditions, such as sun, heat, rain, cold, snow, sleet, mud, etc., as well as constant inundation by waves, saltwater, algae, moss, crustaceans, etc. And, because of their use as piers, walkways, docks, etc., natural wood decking material is further subjected to the harsh conditions from general use.

The life span of the natural wood may be extended by coating the wood with paints, varnishes, sealants, coatings, and other finishes to deter the eventual degradation and rotting of the wood. To further extend the life of the wood it was discovered that pressure treating the wood provided greater durability. However, coated and even pressure treated wood eventually fails subject to harsh conditions; and without constant maintenance and repair, any type of wood deck ultimately needs replacement. Moreover, due to the increasing cost of decking lumber, alternate materials were needed.

Metallic materials, such as steel, aluminum and other alloys may be used, but they suffer from other disadvantages. Although strong and durable, they too suffer from extreme environmental conditions, such as rust, pitting, corrosion, etc., and in proximity to saltwater conditions, these effects are greatly accelerated. Furthermore, metallic systems are heavy, expensive, and require extensive expertise to manufacture, assemble, weld, etc.

Recently, synthetic and composite type materials have been developed that overcome many of the above limitations. They are generally lightweight, easier to manufacture (mold), assemble, and cost effective. They are generally made from reinforced thermoplastics or thermoset type materials. However, these materials require significant reinforcement or complex engineered design to provide the strength needed to sustain regular operating and use conditions. Moreover, recent federal guidelines implemented to promote ecological concerns mandate that any decking materials used for federally funded projects or federal applications must comprise at least 60% light passage open area, i.e., at least 60% of the deck area must allow environmental elements such as, light, air, snow, rain, etc., to pass through.

Synthetic and composite decking materials that meet the federal requirements are not currently available or disclosed in the prior art, and presently are only allowed under an addendum/waiver as they do not meet the federal requirement. The prior art has other disadvantages in commercial applications as well, all of which are overcome by decking of the present disclosure. For example, U.S. Pat. No. 7,500,336 to McGivem et al. discloses a composite material used for decking, but the McGivern openings provide only about 43% light passage.

SUMMARY OF THE DISCLOSURE

Various representative embodiments of a decking system and its components are disclosed herein and comprise of a plurality of interlocking deck planks manufactured using a synthetic material engineered such that at least 60% of the deck plank area provides a pass through for light, water, air and other environmental elements. For example, in one embodiment a deck plank comprises a frame comprising a length, and a width, wherein the deck plank comprises a plurality of elongated, substantially equal, deck plank openings such that the deck plank openings comprise a deck plank openings area of at least 60% of a deck plank area, wherein the deck plank area is defined by the frame's length and width. In other words, a deck plank and deck plank system comprises a plurality of uniform openings, wherein a sum area of the surface, other than the openings, comprises no greater than 40% of an area of the deck plank as outlined by a perimeter of the deck plank.

A deck plank, as part of a complete decking system, comprises a plurality of planar rib elements, wherein each rib element spans perpendicular from a first width side of the deck plank to an opposite, second width side of the deck plank. Each planar rib element further couples perpendicularly to a rib spline at an underside and at a midpoint of the planar rib element, and the rib spline extends along the rib element span. The planar rib elements are spaced evenly apart from a first length side of the deck plank to an opposite, second length side of the deck plank, and the plurality of planar rib elements define a working deck plank surface. The deck plank further comprises a plurality of rib spacers to support and secure a position of adjacent planar rib elements, wherein each rib spacer couples to and between adjacent rib splines, and each rib spacer comprises a spacer plate coupled to a spacer spline, wherein each spacer plate is partially overlapped by adjacent planar rib elements. The deck plank also comprises a plurality of U-shaped support tabs to further support and secure the position of the rib elements, wherein each U-shaped support tab couples perpendicularly between adjacent rib splines, and adjacent planar rib elements overlap a top portion of each U-shaped support tab.

Among various deck plank embodiments the deck plank comprises a plurality of fastening ports adjacent a perimeter of the deck plank, wherein the fastening ports extend from just below the working deck plank surface to a depth, such that a top portion of a fastener secured within the fastening port is recessed or at least flush relative to the working deck plank surface. Various deck plank embodiments also comprise a plurality of interlocking tabs spaced evenly along an external portion of the perimeter of the deck plank to interlock and secure adjacent deck planks, wherein an assembly of deck planks couple to a support structure to complete the desired pier, walkway, dock, etc.

To accommodate various applications, various embodiments of a rectangular deck plank generally comprises the deck plank length to comprise a length of at least 24 inches; wherein at least one of the rib splines, spacer splines, U-shaped support tabs, and a side of the deck plank perimeter comprises a depth of at least 1.5 inches when measured from the working deck plank surface to a bottom side of the at least one of the rib splines, spacer splines, U-shaped support tabs, and side of the deck plank perimeter. Moreover, a top portion of the fastening ports are recessed at least 0.5 inches from the working deck plank surface. Among various deck plank systems, the deck planks are assembled typically using rectangular and triangular shaped planks, although planks having a geometric configuration that is square, hexagonal, octagonal, pentagonal, etc. may be employed.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the decking system may be derived by referring to the detailed description and claims when considered in connection with the following illustrative Figs. In the following Figs., like reference numbers refer to similar elements throughout the Figs.

FIG. 1 representatively illustrates a perspective view of a deck plank depicting a top, front, and left side of the deck plank;

FIG. 2 representatively illustrates a top down view of the deck plank;

FIG. 3 representatively illustrates a perspective close-up view of a portion of the deck plank;

FIG. 4 representatively illustrates a perspective close up view of a portion of the bottom of the deck plank;

FIG. 5 representatively illustrates an assembly of deck planks to demonstrate a representative deck plank system; and

FIG. 6 representatively illustrates a deck plank comprising an alternate geometric configuration.

Elements in the Figs. are illustrated for simplicity and clarity and have not necessarily been rendered according to any particular sequence. For example, steps that may be performed concurrently or in different order are illustrated in the Figs. to help to improve understanding of embodiments of the decking system.

DETAILED DESCRIPTION OF THE DISCLOSURE

A decking system may be described herein in terms of various functional components, and such functional elements may be realized by any number of hardware components configured to perform the specified functions and achieve various results. For example, the decking system may employ deck planks comprising various geometric configurations that comprise various functional elements, e.g., rib elements, spacers, pass through openings, support tabs, interlocking tabs, fastening ports, and the like, which may carry out a variety of functions. In addition, the decking system may be practiced in conjunction with any number of piers, docks, walkways, gangways, etc., and the decking systems described are merely exemplary embodiments. Further, the decking system may employ any number of conventional techniques for manufacturing, assembling, packaging, marketing, distributing, selling and the like.

Various representative embodiments of deck planks may be applied to any system for decking Referring now to FIG. 1, a rectangular deck plank 100 comprises a frame 102 comprising a length 104 and a width 106, and in one embodiment to accommodate commercial applications, length 104 comprises a length of 24 inches. It will be understood by those skilled in the art the reference to widths and lengths throughout this disclosure are merely for convenience, and that lengths referenced throughout generally comprise a greater dimensional value than a width (for a rectangular embodiment), but the width may conversely have a greater dimensional value then the length. With reference to FIG. 2, deck plank 100 comprises a plurality of elongated deck plank openings, exemplified by deck plank openings 208, such that a sum of all the deck plank openings of deck plank 100 comprise a deck plank openings area of at least 60% of a deck plank area, wherein the deck plank area is defined by frame 102's length 104 and width 106. In other words, if the area of all of the deck plank openings were added together, their sum total would amount to at least 60% of the total area of the deck plank, which, again, is determined by the deck plank's frame length and width. For example, a deck plank comprising a rectangular frame comprising a length of 24 inches and a width of 16 inches, the total deck plank area would equal 384 in². Thus, the sum total of the area of all the deck plank openings must equal at least 60% of 384 in², which equals 230.4 in². Obviously, those skilled in the art will appreciate that the deck plank frame's area described and calculated above relates to a rectangular or square geometric shape and that a deck plank area calculation depends upon the specific geometric configuration of the deck plank, whether it be triangular, hexagonal, octagonal etc. Nonetheless, though, the sum area of the deck plank openings, regardless of the deck planks geometric shape, should amount to at least 60% of the deck plank's area. To understand in an alternate manner, a deck plank, such as deck plank 100, comprises a usable surface created by a plurality of planar rib elements (discussed in greater detail below), wherein a sum area of the deck plank surface area comprises no greater than 40% of an area of the deck plank. Among various exemplary embodiments, deck plank 100 in conjunction with a plurality of other individual deck planks interconnect to create a deck plank system, which is configured such that at least 60% of the area of deck plank 100 as well any deck plank system allows a pass through of at least one of an environmental condition, such as; sunlight, rain, snow, sleet, hail, and air. Among some exemplary embodiments, deck plank openings, such as openings 208, are uniform or equal in area, as well as configuration and spacing, however those skilled in the art will understand that openings 208 may comprise of a variety of regularly or irregularly patterned configurations of area, spacing and/or orientation.

Continuing with FIG. 2, deck plank 100 comprises a plurality of planar rib elements, exemplified by planar rib elements 210, wherein each planar rib element 210 spans perpendicularly from a first width side 212 of deck plank 100 to an opposite, second width side 214 of deck plank 100. Each planar rib element 210 suitably couples perpendicularly to a rib spline 316, FIG. 3, at an underside and at a midpoint of each planar rib element 210. Rib spline 316 extends the span of rib element 210 to support its respective planar rib element; and as can be seen with return reference to FIG. 2, planar rib elements 210 are spaced evenly apart between a first length side 220 of deck plank 100 to an opposite second length side 222 of deck 100 plank. As can be seen, it is the plurality of planar rib elements 210 that define a working deck plank surface 224. Those skilled in the art will understand that planar rib elements 210 are integrated to deck plank 100 at an interior portion of each perimeter side of frame 102 such as length sides 220 and 222, and width sides 212 and 214 so as to create a support transition from the plurality of planar rib elements 210 to frame 102. Those skilled in the art will further appreciate that while rib elements 210 are referenced as “planar” and are generally “flat”, in some embodiments rib elements 210 may be beveled, cambered, cupped, convex, concave, or comprise any other configuration so as to facilitate deterring an accumulation of environmental elements such as rain, snow, hail, dirt, etc. In addition, rib elements 210 may comprise a variety of textured surfaces to facilitate a slip proof surface.

In accordance with an exemplary embodiment and with continued reference to FIG. 2, deck plank 100 comprises a plurality of rib spacers, exemplified by rib spacers 230, to support and secure a position of adjacent planar rib elements 210. In this exemplary embodiment and with return reference to FIG. 3, each rib spacer 230 suitably couples between adjacent rib splines 316, and each rib spacer 230 comprises a spacer plate 332 suitably coupled to a spacer spline 334, wherein both the spacer plate 332 and spacer spline 334 couple to adjacent rib splines 316. In this exemplary embodiment and with continued reference to FIG. 3, to maximize deck plank openings 208 each side of spacer plate 332 not coupled to rib splines 316 comprises an arcuate shape 336, but those skilled in the art will understand that such non-coupled spacer plate 332 sides may comprise other geometric configurations. In this exemplary embodiment each spacer plate 332 is partially overlapped by adjacent planar rib elements 210, exemplified by spacer overlap 370. Those skilled in the art will understand that by coupling rib spacers 230 to adjacent rib splines 316, the spacing of rib splines 316, and thus, the spacing of planar rib elements 210 can be maintained. Moreover, since a portion of rib elements 210 overlaps a portion of rib spacer 230 at spacer plate 332, planar rib element 210 is further supported. Among some embodiments and as can be seen among the Figs., rib spacers 230 may be aligned in a column from first length side 220 of deck plank 100 to opposite, second length side 222 of deck plank 100, best be seen by FIG. 2. Since rib spacers 230, in this exemplary embodiment, are aligned in a column from first length side 220 to opposite, second length side 222, rib spacer's 230 corresponding spacer splines 334 are likewise aligned from first length side 220 to opposite, second length side 222. Thus, those skilled in the art will understand that rib splines 316 in conjunction with spacer splines 334 demonstrate a grid support structure for planar rib elements 210 that is more supportive then if rib elements 210 relied upon rib splines 316 alone for support, best seen by grid structure 480 FIG. 4.

In accordance with an exemplary embodiment, and with return reference to FIG. 3, deck plank 100 further comprises a plurality of U-shaped support tabs, exemplified by U-shaped support tabs 340, to further support and secure the position of planar rib elements 210, wherein each U-shaped support tab 340 suitably couples perpendicularly between adjacent rib splines 316; and adjacent planar rib elements 210 overlap a top portion of each U-shaped support tab 340 demonstrated by U-shaped support tab overlap 372. In accordance with the exemplary embodiment and similar to rib spacers 230, U-shaped support tabs 340 are also are aligned in a column from first length side 220 to opposite, second length side 222. Thus, rib elements 210 are even further supported and supplement the support provided by rib splines 316 and rib spacers 230. It is this unique support structure that allows deck plank 100 to effectively operate as a functional deck plank yet comprise an openings area of at least 60% of a deck plank area.

In accordance with an exemplary embodiment and with return reference to FIG. 2, deck plank 100 comprises a plurality of fastening ports, exemplified by fastening ports 250, proximate to first length side 220 and second length side 222 of deck plank 100. As can be seen, the plurality of fastening ports 250 are evenly spaced along the entire length sides, and as such are able to accommodate a variety of support structure configurations that deck plank 100 might be secured. In one embodiment fastening ports 250 are spaced evenly apart at 1.25 inch intervals. Among various embodiments, fastening ports 250 extend from just below the working deck plank surface to a depth, such that, a top portion of a fastener, such as a screw, secured within fastening port 250 is recessed or at least flush relative to the working deck plank surface. In one embodiment, a top portion of fastening ports 250 are recessed 0.50 inches below the working deck plank surface. The recessed configuration of fastening ports 250 can best be seen by reference to FIGS. 1 and 3. In accordance with the exemplary embodiment, and as can be seen among the Figs, fastening ports 250 generally comprise a circular configuration to accommodate a fastening screw so as to secure deck plank 100 to a support structure (not shown). In some embodiments, fastening ports 250 may be threaded to further facilitate receiving and securing a fastening screw. In accordance with an exemplary embodiment and with reference among the Figs., it is apparent that fastening ports 250 located at the four corners of deck plank 100 are slightly elongated or oval shaped, and those skilled in the art will understand that the elongated corner fastening ports 250 are configured such so as to accommodate any slight variations in aligning and securing deck plank 100 to a support structure. It will be further understood that the plurality of fastening ports 250 may also be incorporated adjacent along each of the width sides as well, such as first width side 212 and/or second width side 214. And in some embodiments, fastening ports 250 may be incorporated among any of the openings 208, but in the exemplary embodiment shown, fastening ports 250 are incorporated within openings 208 adjacent to length sides 220 and 222.

In accordance with an exemplary embodiment and with reference to FIG. 1, deck plank 100 further comprises a plurality of interlocking tabs, exemplified by interlocking tabs 180, spaced along an external portion of perimeter 160 of deck plank 100 to interlock and secure adjacent deck planks. In the exemplary embodiment, interlocking tabs 180 align with the column of U-shaped support tabs 340, but may be aligned or positioned in a variety of configurations. Those skilled in the art will understand that a plurality of deck planks may interlock to create a complete deck plank system 501, as seen with reference to FIG. 5; and those skilled in the art will understand how a deck plank system may comprise a combination of rectangular and alternate shaped deck planks, such as the triangular deck plank shown, wherein a triangular deck plank 600 is representatively illustrated by FIG. 6. Continuing with interlocking tabs, interlocking tabs 180 are configured such that a male portion of one deck plank may be received by a corresponding female portion of an adjacent deck plank, thus interlocking tabs of adjacent deck planks mate accordingly to complete a coupling of adjacent deck planks Interlocking tabs 180 are shown positioned along an external portion of perimeter 160 at first length side 220 and second length side 222, but other embodiments may comprise interlocking tabs along width sides as well, such as width sides 212 and/or 214. Moreover, one skilled in the art will understand that the interlocking tabs shown are merely one configuration to couple adjacent deck planks, but other coupling mechanisms now known or developed in the future may be employed. For example, adjacent deck planks may be coupled using various overlaps, welds, screws, pins, clasps, etc.

In accordance with an exemplary embodiment and with reference to FIG. 3, a few, some, or all of intersections, such as intersection 360, between a rib spline 316 and/or a U-shaped support tab 340 or between a rib spline 316 and/or a spacer spline 334 comprise additional beading 362. As can be seen, those skilled in the art will understand that beading 362 provides additional support for planar rib element 210 by reinforcing the various intersections, yet without detracting from any of openings 208.

Among various exemplary embodiments, deck plank 100 and the various components and elements that comprise deck plank 100 are generally fabricated using a thermoset or thermoplastic type material. In some embodiments, deck plank 100 material may alternately comprise a composite material, such as fibrous impregnated composite material, such as carbon fiber or glass fiber reinforced material. Moreover, the various elements described throughout this disclosure may be individually coupled and/or assembled, but in a preferred embodiment, the various components are molded as parts of a single integrated deck plank unit.

Among various exemplary embodiments, and to accommodate general commercial applications, at least one of rib splines, spacer splines, U-shaped support tabs, and a side of the deck plank perimeter comprises a depth of at least 1.5 inches when measured from the working deck plank surface, such as working deck plank surface 224 to a bottom side of the at least one of the rib splines, spacer splines, U-shaped support tabs, and side of the deck plank perimeter.

In the foregoing specification, a decking system and its components has been described with reference to specific exemplary embodiments. Various modifications and changes may be made, however, without departing from the scope of the decking system and its components as set forth in the claims. For example, this disclosure emphasizes the importance of the deck plank openings, in total, comprise an area that is at least 60% of the total area of the deck plank, however, some embodiments may comprise a deck plank that may not meet such specification, but rather benefits from the unique architecture of the components as disclosed and shown. The specification and Figs. are illustrative, rather than restrictive, and modifications are intended to be included within the scope of the decking system. Accordingly, the scope of the decking system and its components should be determined by the claims and their legal equivalents rather than by merely the embodiments described. For example, the components and/or elements recited in the claims may be assembled or otherwise operationally configured in a variety of permutations and are accordingly not limited to the specific configuration recited in the claims.

Benefits, other advantages and solutions to problems have been described above with regard to particular embodiments; however, any benefit, advantage, solution to problem or any element that may cause any particular benefit, advantage or solution to occur or to become more pronounced are not to be construed as critical, required, or essential features or components of any or all the claims.

As used herein, the terms “comprise”, “comprises”, “comprising”, “having”, “including”, “includes”, “is” or any variation thereof, are intended to reference a non-exclusive inclusion, such that an article, composition, device, apparatus, system and the like that comprises a list of elements does not include only those elements recited, but may also include other elements not expressly listed or inherent to such, article, composition, device, apparatus, system, etc. Other combinations and/or modifications of the above-described structures, arrangements, applications, proportions, elements, materials or components used in the practice of the decking system and its components, in addition to those not specifically recited, may be varied or otherwise particularly adapted to specific environments, manufacturing specifications, design parameters or other operating requirements without departing from the general principles of the same. 

I claim:
 1. A deck plank comprises: a frame comprising a length, and a width, wherein the deck plank comprises a plurality of elongated deck plank openings such that the plurality of elongated deck plank openings comprise a deck plank openings area of at least 60% of a deck plank area, wherein the deck plank area is defined by the frame's length and width; a plurality of planar rib elements, wherein each rib element spans perpendicular from a first width side of the deck plank to an opposite second width side of the deck plank, wherein each rib element couples perpendicular to a rib spline at an underside and at a midpoint of the rib element, and the rib spline extends along the rib element span; the rib elements are spaced evenly apart from a first length side of the deck plank to an opposite, second length side of the deck plank; the plurality of rib elements define a working deck plank surface; a plurality of rib spacers to support and secure a position of adjacent rib elements, wherein each rib spacer couples between adjacent rib splines, and each rib spacer comprises a spacer plate coupled to a spacer spline, wherein each spacer plate is partially overlapped by adjacent rib elements; a plurality of U-shaped support tabs to further support and secure the position of the rib elements, wherein each support tab couples perpendicularly between adjacent rib splines; adjacent rib elements overlap a top portion of each U-shaped support tab; wherein the deck plank further comprises a plurality of fastening ports adjacent a perimeter of the deck plank; the fastening ports extend from just below the working deck plank surface to a depth, such that a top portion of a fastener secured within the fastening port is recessed relative to the working deck plank surface; and wherein the deck plank further comprises a plurality of interlocking tabs spaced evenly along an external portion of the perimeter of the deck plank to interlock and secure adjacent deck planks.
 2. The deck plank of claim 1, wherein the spacer plates are aligned in a column from the one length side of the deck plank to the opposite length side of the deck plank.
 3. The deck plank of claim 2, wherein the U-shaped support tabs are aligned in a column from the one length side of the deck plank to the opposite length side of the deck plank.
 4. The deck plank of claim 3, wherein the interlocking tabs align with the U-shaped support tabs column.
 5. The deck plank of claim 3, wherein opposite sides of the spacer plates that are not coupled to the rib splines, comprise an arcuate shape so as to further maximize the deck plank openings area.
 6. The deck plank of claim 5, wherein the fastening ports are generally circular and threaded to receive securing screws.
 7. The deck plank of claim 6, wherein the deck plank comprises the deck length sides to comprise a length of at least 24 inches.
 8. The deck plank of claim 7, wherein at least one of the rib splines, spacer splines, U-shaped support tabs, and a side of the deck plank perimeter comprises a depth of at least 1.5 inches when measured from the working deck plank surface to a bottom side of the at least one of the rib splines, spacer splines, U-shaped support tabs, and side of the deck plank perimeter.
 9. The deck plank of claim 6, wherein a top portion of the fastening ports are recessed at least 0.5 inches from the working deck plank surface.
 10. A deck plank comprises: a surface, comprising a plurality of uniform openings, wherein a sum area of the surface comprises no greater than 40% of an area of the deck plank as outlined by a perimeter of the deck plank.
 11. The deck plank of claim 10, wherein the surface comprises a plurality of parallel rib elements that span lengthwise from a first width side of the deck plank across to a second width side of the deck plank.
 12. The deck plank of claim 10, wherein the deck plank comprises at least one of a rectangular, square, triangular, hexagonal, octagonal, and pentagonal geometric configuration.
 13. The deck plank of claim 12, wherein the deck plank comprises of at least one of a thermoplastic or a thermoset molded material element.
 14. The deck plank of claim 11, wherein an area of each of the uniform openings are substantially equal.
 15. The deck plank of claim 14, wherein the uniform openings adjacent a first length side and a second length side further comprise a plurality of regularly spaced, recessed fastening supports within each uniform opening.
 16. The deck plank of claim 15, wherein the rib elements are fixed in their orientation by a plurality of rib spacers and U-shaped support tabs.
 17. A deck plank system comprises; a plurality of individual deck planks interconnected such that at least 60% of an area of the deck plank system allows a pass through of at least one of an environmental condition from the list of; sunlight, rain, snow, sleet, hail, and air.
 18. The deck plank system of claim 17, wherein the plurality of individual deck planks comprises of at least one of a thermoplastic and a thermoset material.
 19. The deck plank system of claim 18 comprising an assembly of rectangular and triangular geometric individual deck planks.
 20. The deck plank system of claim 19, wherein the deck plank system affixes to a deck plank system support structure. 